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1600 YRM 1360 General

General
This section has the description and repair procedures The end caps of the steering cylinder also serve as the
for the steering axle. axle mounts for the cylinder. The piston rod extends
from both ends of the cylinder and is connected to the
The steering axle assembly includes an axle frame, tie rods which are connected to the spindle assemblies.
steering cylinder, two spindle assemblies, and two hub
assemblies. The steering axle is articulated and is
connected to the frame by center pivot mounts. The
center pivot mounts permit the steering axle to move in
the frame mount when the lift truck travels over rough
surfaces. See Figure 1.

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General 1600 YRM 1360

NOTE: MOUNTS AND TIRES MAY BE DIFFERENT BETWEEN TRUCK MODELS.


A. CUSHION TRUCKS ONLY B. PNEUMATIC TRUCKS ONLY
1. AXLE FRAME 6. STEERING CYLINDER
2. STEERING DIRECTION SENSOR CABLE 7. TIE ROD
BRACKET 8. SPINDLE ASSEMBLY
3. STEERING DIRECTION SENSOR 9. MOUNT
4. MOUNT 10. CUSHION TIRE WHEEL ASSEMBLY
5. MOUNT BRACKET 11. PNEUMATIC HUB ASSEMBLY

Figure 1. Steering Axle

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1600 YRM 1360 Steering Axle Assembly Repair

Steering Axle Assembly Repair


REMOVE ERC22-35VG (ERC045-070VG) 2. Slide floor jack under steering axle. Raise floor jack
(A968), ERC16-20VA (ERC030-040VA) until it holds the weight of the axle assembly.
(A969) AND ERC40-55VH, ERC50VHS NOTE: Tag hydraulic lines prior to disconnecting from
(ERC80-120VH, ERC100VHS) (A938) steering cylinder to aid in the correct connection of hy-
draulic lines during installation.
WARNING 3. Disconnect hydraulic hoses at steering cylinder. In-
PUTTING THE LIFT TRUCK ON BLOCKS stall plug fittings in cylinder and put caps on hy-
draulic hoses. Plug fittings will prevent spindles
The lift truck must be put on blocks for some
from turning as axle is removed from under the lift
types of maintenance and repair. The removal
truck.
of the mast, drive axle, battery, or counterweight
assemblies will cause large changes in the center 4. Remove four capscrews that fasten the mount
of gravity. When the lift truck is put on blocks, put brackets under the rubber mounts.
additional blocks in the following positions:
• If the mast and drive axle are removed, put blocks See Figure 2 for lift truck models
under the counterweight so the lift truck cannot • ERC22-35VG (ERC045-070VG) (A968)
fall backward.
• If the counterweight is removed, put blocks under See Figure 3 for lift truck models
the mast so that the lift truck cannot fall forward. • ERC16-20VA (ERC030-040VA) (A969)

Put the lift truck on blocks on a solid, even, and See Figure 4 for lift truck models
level surface. Verify the blocks or stands have • ERC40-55VH, ERC50VHS (ERC80-120VH,
enough capacity to hold the lift truck. Use ad- ERC100VHS) (A938)
ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the lifting
devices used during repairs can lift the weight of
the parts and assemblies.

See the Operating Manual or Periodic Maintenance


section for your lift truck model, for the procedures
to put the lift truck on blocks.

The steering axle can be removed without removing the


counterweight.

1. Place the lift trucks on blocks. The procedure for


placing the lift truck on blocks may be found in the
Operating Manual or in one of the following service
manuals:

Periodic Maintenance 8000 YRM 1364 for lift truck 1. CAPSCREW


models 2. WASHER
• ERC22-35VG (ERC045-070VG) (A968) 3. NUT
4. REAR MOUNT BRACKET
Periodic Maintenance 8000 YRM 1442 for lift truck 5. STEER AXLE
models 6. FRONT MOUNT BRACKET
• ERC16-20VA (ERC030-040VA) (A969) Figure 2. Steer Axle Removal ERC22-35VG
Periodic Maintenance 8000 YRM 1577 for lift truck (ERC045-070VG) (A968)
models
• ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)

3
Steering Axle Assembly Repair 1600 YRM 1360

NOTE: The steering direction sensor is an op-


tional feature on ERC22-35VG (ERC045-070VG)
(A968), ERC16-20VA (ERC030-040VA) (A969)
and ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) lift trucks.

5. Carefully lower the floor jack enough to disconnect,


if installed, steering direction sensor cable from the
main wiring harness.

See Figure 5 for lift truck models


• ERC22-35VG (ERC045-070VG) (A968)

See Figure 6 for lift truck models


• ERC16-20VA (ERC030-040VA) (A969)

See Figure 7 for lift truck models


1. CAPSCREW • ERC40-55VH, ERC50VHS (ERC80-120VH,
2. WASHER ERC100VHS) (A938)
3. NUT
4. REAR MOUNT BRACKET 6. Remove the steer axle from the under the lift truck.
5. STEER AXLE
6. FRONT MOUNT BRACKET DISASSEMBLE ERC22-35VG
Figure 3. Steer Axle Removal ERC16-20VA
(ERC045-070VG) (A968), ERC16-20VA
(ERC030-040VA) (A969) (ERC030-040VA) (A969) AND ERC40-55VH,
ERC50VHS (ERC80-120VH, ERC100VHS)
(A938)
1. Place steering axle on blocks so the wheels just
touch the floor.

2. Remove hub cap, cotter pin, castle nut, and washer.


Discard cotter pin.

See Figure 5 for lift truck models


• ERC22-35VG (ERC045-070VG) (A968)

See Figure 6 for lift truck models


• ERC16-20VA (ERC030-040VA) (A969)

See Figure 7 for lift truck models


1. CAPSCREW
2. WASHER • ERC40-55VH, ERC50VHS (ERC80-120VH,
3. NUT ERC100VHS) (A938)
4. REAR MOUNT BRACKET
5. STEER AXLE
6. FRONT MOUNT BRACKET

Figure 4. Steer Axle Removal ERC40-55VH,


ERC50VHS (ERC80-120VH, ERC100VHS) (A938)

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1600 YRM 1360 Steering Axle Assembly Repair

1. HUB CAP 11. OIL SEAL


2. CASTLE NUT 12. AXLE ASSEMBLY
3. COTTER PIN 13. MOUNT
4. WASHER 14. CAPSCREW
5. OUTER BEARING CONE 15. BRACKET
6. OUTER BEARING CUP 16. WASHER
7. SOLID TIRE WHEEL 17. LOCKNUT
8. INNER BEARING CUP 18. STEERING DIRECTION SENSOR
9. INNER BEARING CONE 19. STEERING DIRECTION SENSOR CABLE
10. WEAR RING BRACKET

Figure 5. Steering Axle Assembly for ERC22-35VG (ERC045-070VG) (A968)

5
Steering Axle Assembly Repair 1600 YRM 1360

1. HUB CAP 9. INNER BEARING CONE


2. CASTLE NUT 10. OIL SEAL
3. COTTER PIN 11. AXLE ASSEMBLY
4. WASHER 12. MOUNT
5. OUTER BEARING CONE 13. CAPSCREW
6. OUTER BEARING CUP 14. BRACKET
7. SOLID TIRE WHEEL 15. WASHER
8. INNER BEARING CUP 16. LOCKNUT

Figure 6. Steering Axle Assembly for ERC16-20VA (ERC030-040VA) (A969)

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1600 YRM 1360 Steering Axle Assembly Repair

1. HUB CAP 11. OIL SEAL


2. CASTLE NUT 12. AXLE ASSEMBLY
3. COTTER PIN 13. MOUNT
4. WASHER 14. CAPSCREW
5. OUTER BEARING CONE 15. BRACKET
6. OUTER BEARING CUP 16. WASHER
7. SOLID TIRE WHEEL 17. LOCKNUT
8. INNER BEARING CUP 18. STEERING DIRECTION SENSOR
9. INNER BEARING CONE 19. STEERING DIRECTION SENSOR CABLE
10. WEAR RING BRACKET

Figure 7. Steering Axle Assembly for Lift Trucks ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS)
(A938)

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Steering Axle Assembly Repair 1600 YRM 1360

NOTE: Identify and tag the outer and inner bearing


cones so they can be reassembled in their original WARNING
locations. Compressed air is used for cleaning or drying pur-
poses, or for clearing restrictions. Wear protective
3. Remove outer bearing cone from the wheel. clothing (goggles/shield, gloves, etc.) to avoid in-
jury to personnel.
4. Remove wheel from spindle.
1. Clean bearing cones by placing them in a wire bas-
NOTE: For correct orientation during installation, note ket and immersing in a container of fresh solvent.
the position of the oil seal during removal. Agitate the bearing cones in the solvent to remove
NOTE: The wear ring may not be present on all steering all traces of old lubricant.
axles. 2. Clean all remaining components, except the oil
5. Remove inner bearing cone, wear ring (if present) seals and mounts, with solvent.
and oil seal from spindle. 3. Clean the oil seals and rubber mounts in warm
See Figure 5 for lift truck models soapy water. Rinse with clean warm water and al-
• ERC22-35VG (ERC045-070VG) (A968) low to air dry.

See Figure 6 for lift truck models 4. After cleaning, dry bearing cones with compressed
• ERC16-20VA (ERC030-040VA) (A969) air. Take care to prevent spinning the bearing cones
when using a compressed air jet.
See Figure 7 for lift truck models
• ERC40-55VH, ERC50VHS (ERC80-120VH, 5. Immediately wrap bearing cones in a lint-free cloth
ERC100VHS) (A938) to protect them from dust and other foreign matter.

6. Remove the mounts from the axle assembly. INSPECT


NOTE: Bearing cones are to be replaced as sets. If one 1. Inspect bearing cones for burned or damaged
bearing cone has been determined to be unserviceable, rollers. If either condition exists, replace both sets
then both must be replaced. of bearing cones and bearing cups.

7. If the bearing cones are to be replaced, remove the 2. Inspect bearing cups for signs of overheating or
inner and outer bearing cups from the wheel using scoring. If either condition exists, replace both sets
a brass drift pin. of bearing cones and bearing cups.

8. Repeat Step 1 through Step 7 for the other wheel. 3. Inspect the rubber mounts for signs of damage or
cracking. Replace, if necessary.
CLEAN
4. Inspect the oils seals and wear rings for any dam-
age. Replace, if damaged.
WARNING
Cleaning solvents can be flammable and toxic and 5. Inspect spindle assemblies and tie rods for signs of
can cause skin irritation. When using cleaning damage. Replace, if necessary, in accordance with
solvents, always follow the solvent manufacturer’s Spindles, Bearings and Tie Rods Repair.
recommended safety procedures.
6. Inspect the remainder of the axle assembly for dam-
age, and repair or replace as necessary.

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1600 YRM 1360 Steering Axle Assembly Repair

ASSEMBLE ERC22-35VG (ERC045-070VG) b. Tighten castle nut to 68 N•m (50 lbf ft) while
(A968), ERC16-20VA (ERC030-040VA) rotating the wheel in both directions to properly
(A969) AND ERC40-55VH, ERC50VHS seat the bearings.
(ERC80-120VH, ERC100VHS) (A938) c. Loosen the castle nut 1/4 turn.
1. If bearing cups have been removed, use a press to d. Tighten nut to 3 N•m (27 lbf in).
install new bearing cups in wheel. See Figure 8.
e. Pull on the wheel assembly to ensure that there
2. For specified lubricant see is no end play. If there is excessive end play,
reassemble washer and repeat Step a through
Periodic Maintenance 8000 YRM 1364 for lift truck Step c.
model
• ERC22-35VG (ERC045-070VG) (A968) 6. Install new cotter pin in castle nut. If cotter pin can-
not be installed, tighten castle nut to the first align-
Periodic Maintenance 8000 YRM 1442 for lift truck ment position where the cotter pin can be installed.
model
• ERC16-20VA (ERC030-040VA) (A969) 7. Install hub cap.
Periodic Maintenance 8000 YRM 1577 for lift truck 8. Repeat Step 1 through Step 7 for other wheel.
models
• ERC40-55VH, ERC50VHS (ERC80-120VH, NOTE: Ensure that the washer is seated properly
ERC100VHS) (A938) against the bearing cone and not against the shaft
shoulder before tightening the castle nut.
Verify bearings are filled with grease.
NOTE: Perform Step 9 through Step 12 for lift truck
3. Install oil seal, as noted during removal, wear ring models ERC16-20VA (ERC030-040VA) (A969).
(if removed), and inner bearing cone on spindle.
9. Install the castle nut as follows:
CAUTION a. Install and tighten the castle nut to seat the
DO NOT damage the seals during installation. bearing, and back off completely.

4. Carefully slide wheel onto spindle. Install outer b. Tighten castle nut to 200 N•m (148 lbf ft) while
bearing cone and install washer. rotating the wheel in both directions to properly
seat the bearings.
NOTE: Ensure that the washer is seated properly
against the bearing cone and not against the shaft c. Loosen the castle nut 1/4 turn.
shoulder before tightening the castle nut.
d. Tighten nut to 12 N•m (106 lbf in).
NOTE: Perform Step 5 through Step 8 for lift truck mod-
els ERC22-35VG (ERC045-070VG) (A968). e. Pull on the wheel assembly to ensure that there
is no end play. If there is excessive end play,
5. Install the castle nut as follows: reassemble washer and repeat Step a through
Step c.
a. Install and tighten the castle nut to seat the
bearing, and back off completely.

9
Steering Axle Assembly Repair 1600 YRM 1360

10. Install new cotter pin in castle nut. If cotter pin can- INSTALL ERC22-35VG (ERC045-070VG)
not be installed, tighten castle nut to the first align- (A968)
ment position where the cotter pin can be installed.
1. Install rubber mounts and top mount(s) on axle.
11. Install hub cap. Verify that the face of rubber mount with the word
"TOP" and the arrow (pointing up) is facing away
12. Repeat Step 1 through Step 4 and Step 9 through
from the steer axle. See Figure 9.
Step 11 for other wheel.
2. Apply lubricant (that is approved for use with rub-
NOTE: Perform Step 13 through Step 15 for lift truck
ber) to rubber mount. The lubricant is used to ease
models
assembly of the rubber mounts into lift truck frame
• ERC40-55VH, ERC50VHS (ERC80-120VH,
and mount brackets.
ERC100VHS) (A938)
3. Using a floor jack, position the steering axle under
13. Install the castle nut as follows:
the frame.
a. Install castle nut and tighten to 203 N•m
4. If the lift truck is equipped with the steering direc-
(150 lbf ft) while rotating the wheel in both
tion sensor option, connect steering direction sen-
directions to properly seat the bearings.
sor cable to the main wiring harness. See Figure 5.
b. Back off castle nut until wheel turns freely with
5. Lift the steer axle into position on the lift truck frame,
no end play. Torque should be less than 27 N•m
and install the rear and front mount brackets, four
(238 lbf in).
washers, four capscrews, and four nuts. Tighten
c. If there is excessive end play, reassemble capscrews to 90 N•m (66 lbf ft). See Figure 10.
washer and repeat Step a and Step b.
6. Remove plugs and caps and connect hydraulic
d. Re-torque castle nut to 34 N•m (25 lbf ft) and lines to steering cylinder as noted during removal.
lock in place at first alignment position which
7. Remove the floor jack from under the lift truck, and
occurs at or above 34 N•m (25 lbf ft).
remove the lift truck from the blocks.
e. Install new cotter pin and bend one prong over
8. Operate steering system to remove air from sys-
castle nut. Bend other prong over spindle and
tem. Turn steering wheel several times from one
cut flush with end of spindle.
stop to the other. Check for hydraulic leaks.
14. Install hub cap.

15. Perform Step 1 through Step 4 and Step 13 and


Step 14 for other wheel.

10
1600 YRM 1360 Steering Axle Assembly Repair

1. RUBBER MOUNT 3. STEER AXLE


2. TOP MOUNT

Figure 9. Mount Installation for Lift truck Model


ERC22-35VG (ERC045-070VG) (A968)

1. WASHER
2. HUB CAP
3. COTTER PIN
4. CASTLE NUT
5. BEARING CONE
6. BEARING CUP
7. SPINDLE
8. WEAR RING
9. OIL SEAL

Figure 8. Bearing Arrangement for Lift Truck


Models ERC22-35VG (ERC045-070VG) (A968),
ERC16-20VA (ERC030-040VA) (A969) and
ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
1. CAPSCREW
2. WASHER
3. NUT
4. REAR MOUNT BRACKET
5. STEER AXLE
6. FRONT MOUNT BRACKET

Figure 10. Steer Axle Installation for Lift Truck


Model ERC22-35VG (ERC045-070VG) (A968)

11
Steering Axle Assembly Repair 1600 YRM 1360

INSTALL ERC16-20VA (ERC030-040VA)


(A969)
1. Install rubber mounts and top mount(s) on axle.
Verify that the face of rubber mount with the word
"TOP" and the arrow (pointing up) is facing away
from the steer axle. See Figure 11.

2. Apply lubricant (that is approved for use with rub-


ber), to rubber mount. The lubricant is used to ease
assembly of the rubber mounts into lift truck frame
and mount brackets.

3. Using a floor jack, position the steering axle under


the frame.

4. If the lift truck is equipped with the steering direc-


tion sensor option, connect steering direction sen- 1. RUBBER MOUNT 3. STEER AXLE
2. TOP MOUNT
sor cable to the main wiring harness. See Figure 6.
Figure 11. Mount Installation for Lift Truck Model
5. Lift the steer axle into position on the lift truck frame,
ERC16-20VA (ERC030-040VA) (A969)
and install the rear and front mount brackets, four
washers, four capscrews, and four nuts. Tighten
capscrews to 41 to 49 N•m (30.2 to 36.1 lbf ft). See
Figure 12.

6. Remove plugs and caps and connect hydraulic


lines to steering cylinder as noted during removal.

7. Remove the floor jack from under the lift truck, and
remove the lift truck from the blocks.

8. Operate steering system to remove air from sys-


tem. Turn steering wheel several times from one
stop to the other. Check for hydraulic leaks.

1. CAPSCREW
2. WASHER
3. NUT
4. REAR MOUNT BRACKET
5. STEER AXLE
6. FRONT MOUNT BRACKET

Figure 12. Steer Axle Installation for Lift Truck


Model ERC16-20VA (ERC030-040VA) (A969)

12
1600 YRM 1360 Steering Axle Assembly Repair

INSTALL ERC40-55VH, ERC50VHS


(ERC80-120VH, ERC100VHS) (A938)
1. Install rubber mounts and top mount(s) on axle.
Verify that the face of rubber mount with the word
"TOP" and the arrow (pointing up) is facing away
from the steer axle. See Figure 13.

2. Apply lubricant (that is approved for use with rub-


ber) to rubber mount. The lubricant is used to ease
assembly of the rubber mounts into lift truck frame
and mount brackets.

3. Using a floor jack, position the steering axle under


the frame.

4. If the lift truck is equipped with the steering direc-


tion sensor option, connect steering direction sen-
sor cable to the main wiring harness. See Figure 7. 1. RUBBER MOUNT
2. TOP MOUNTS
3. REAR MOUNT BRACKET
5. Lift the steer axle into position on the lift truck frame, 4. STEER AXLE
and install the rear and front mount brackets, eight 5. WASHER
washers, four capscrews, and four nuts. Tighten 6. NUT
capscrews to 225 to 280 N•m (166 to 207 lbf ft). 7. FRONT MOUNT BRACKET
See Figure 14. 8. CAPSCREW

6. Remove plugs and caps and connect hydraulic Figure 13. Mount Installation, Lift Trucks
lines to steering cylinder as noted during removal. ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
7. Remove the floor jack from under the lift truck, and
remove the lift truck from the blocks.

8. Operate steering system to remove air from sys-


tem. Turn steering wheel several times from one
stop to the other. Check for hydraulic leaks.

1. CAPSCREW
2. WASHER
3. NUT
4. REAR MOUNT BRACKET
5. STEER AXLE
6. FRONT MOUNT BRACKET

Figure 14. Steer Axle Installation, Lift Trucks


ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)

13
Steering Axle Assembly Repair 1600 YRM 1360

REMOVE ERP22-35VL (ERP045-070VL) 2. Place the lift trucks on blocks. The procedure for
(A976) AND ERP40-50VM (ERP080-100VM) placing the lift truck on blocks may be found in the
(A985) Operating Manual or in one of the following service
manuals:

WARNING Periodic Maintenance 8000 YRM 1372 for lift truck


PUTTING THE LIFT TRUCK ON BLOCKS models
• ERP22-35VL (ERP045-070VL) (A976)
The lift truck must be put on blocks for some
types of maintenance and repair. The removal Periodic Maintenance 8000 YRM 1541 for lift truck
of the mast, drive axle, battery, or counterweight models
assemblies will cause large changes in the center • ERP40-50VM (ERP080-100VM) (A985)
of gravity. When the lift truck is put on blocks, put
3. Slide floor jack under steering axle. Raise lifting
additional blocks in the following positions:
device until it holds the weight of the axle assembly.
• If the mast and drive axle are removed, put blocks
under the counterweight so the lift truck cannot NOTE: Tag hydraulic lines prior to disconnecting from
fall backward. steering cylinder to aid in the correct connection of the
• If the counterweight is removed, put blocks under hydraulic lines during installation.
the mast so that the lift truck cannot fall forward.
4. Disconnect hydraulic lines at steering cylinder. In-
Put the lift truck on blocks on a solid, even, and stall plug fittings in cylinder and put caps on hy-
level surface. Verify the blocks or stands have draulic lines. Plug fittings will prevent spindles from
enough capacity to hold the lift truck. Use ad- turning as axle is removed from under the lift truck.
ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the lifting NOTE: Perform Step 5 and Step 6 for lift truck model
devices used during repairs can lift the weight of ERP22-35VL (ERP045-070VL) (A976) only.
the parts and assemblies.
5. Remove two lower nuts, capscrews, and washers
See the Operating Manual or Periodic Maintenance from the battery box and front mount bracket. See
section for your lift truck model, for the procedures Figure 15.
to put the lift truck on blocks.

The steering axle can be removed without removing the


counterweight.

1. Remove the battery from the lift truck. The proce-


dure for removing the battery may be found in the
Operating Manual or in one of the following ser-
vice manuals:

Periodic Maintenance 8000 YRM 1372 for lift truck


models
• ERP22-35VL (ERP045-070VL) (A976)

Periodic Maintenance 8000 YRM 1541 for lift truck


models 1. CAPSCREW
• ERP40-50VM (ERP080-100VM) (A985) 2. WASHER
3. BATTERY COMPARTMENT
4. FRONT MOUNT BRACKET
5. NUT

Figure 15. Steer Axle Replacement ERP22-35VL


(ERP045-070VL) (A976)

14
1600 YRM 1360 Steering Axle Assembly Repair

6. Remove the top capscrew and washer from the bat- See Figure 16 for lift truck models
tery box and front mount bracket. See Figure 15. • ERP22-35VL (ERP045-070VL) (A976)

7. Remove two capscrews, washers, and rear mount See Figure 17 for lift truck models
bracket. • ERP40-50VM (ERP080-100VM) (A985)

See Figure 16 for lift truck model NOTE: The steering direction sensor is standard
• ERP22-35VL (ERP045-070VL) (A976) on ERP22-35VL (ERP045-070VL) (A976) and
ERP40-50VM (ERP080-100VM) (A985) lift trucks.
See Figure 17 for lift truck model
• ERP40-50VM (ERP080-100VM) (A985) 9. Carefully lower the floor jack enough to remove cap-
screw and cover to disconnect steering direction
NOTE: The front mount bracket may not be able to be sensor cable from the main wiring harness, and re-
removed until the steering axle is lowered during Step 9. move the main wiring harness from the conduit clip
located on the steering axle. See Figure 18. Install
8. Remove two capscrews, washers, hydraulic hose
cover and capscrew. Move the steer axle clear of
mounting brackets, and front mount bracket from
the lift truck.
the counterweight.

1. WASHER 5. STEER AXLE


2. CAPSCREW 6. PNEUMATIC HUB
3. REAR MOUNT BRACKET 7. RUBBER MOUNTS
4. FRONT MOUNT BRACKET

Figure 16. Steer Axle Removal ERP22-35VL (ERP045-070VL) (A976)

15
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